US5376877A - Engine-driven generator - Google Patents
Engine-driven generator Download PDFInfo
- Publication number
- US5376877A US5376877A US07/897,380 US89738092A US5376877A US 5376877 A US5376877 A US 5376877A US 89738092 A US89738092 A US 89738092A US 5376877 A US5376877 A US 5376877A
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- alternating potential
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- alternator
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- 238000002485 combustion reaction Methods 0.000 claims abstract description 15
- 230000001419 dependent effect Effects 0.000 claims abstract description 6
- 238000000034 method Methods 0.000 claims description 18
- 230000006870 function Effects 0.000 claims description 8
- 230000003247 decreasing effect Effects 0.000 claims description 4
- 230000033228 biological regulation Effects 0.000 abstract description 10
- 238000010586 diagram Methods 0.000 description 4
- 238000004804 winding Methods 0.000 description 3
- 230000008859 change Effects 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 239000000446 fuel Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000012217 deletion Methods 0.000 description 1
- 230000037430 deletion Effects 0.000 description 1
- 230000008571 general function Effects 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 230000004044 response Effects 0.000 description 1
- 230000001360 synchronised effect Effects 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
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Classifications
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
- H02P9/00—Arrangements for controlling electric generators for the purpose of obtaining a desired output
- H02P9/04—Control effected upon non-electric prime mover and dependent upon electric output value of the generator
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02B—INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
- F02B63/00—Adaptations of engines for driving pumps, hand-held tools or electric generators; Portable combinations of engines with engine-driven devices
- F02B63/04—Adaptations of engines for driving pumps, hand-held tools or electric generators; Portable combinations of engines with engine-driven devices for electric generators
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02B—INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
- F02B63/00—Adaptations of engines for driving pumps, hand-held tools or electric generators; Portable combinations of engines with engine-driven devices
- F02B63/04—Adaptations of engines for driving pumps, hand-held tools or electric generators; Portable combinations of engines with engine-driven devices for electric generators
- F02B63/042—Rotating electric generators
Definitions
- This invention relates generally to power generating equipment and, more particularly, to engine-driven generators.
- Known portable power generators typically include an internal combustion engine turning an alternator designed to provide a 120 or 240 volt, 50 or 60 hertz alternating current output.
- alternator designed to provide a 120 or 240 volt, 50 or 60 hertz alternating current output.
- One characteristic of such prior power generators is that, in use, the engine speed is held substantially constant regardless of the actual load. This is necessary because, in such generators, the output frequency is a direct function of engine speed. Running the engine at a constant (usually high) speed results in excessive noise, vibration and fuel consumption, particularly where the load is relatively light and maximum engine power is not required.
- multiple pole alternators are used to permit the use of lower synchronous engine speeds, considerable unused engine capacity is frequently available. This is wasteful and makes the generator larger, heavier and more expensive than it needs to be.
- alternators are not run at their maximum power output levels. At a given engine speed, such alternators typically provide maximum power when the alternator output voltage drops to about 70% of the no load voltage. Such a voltage drop, however, is unacceptable in practice, and the usual practice is to run alternators at far less than their maximum power output levels. Thus, to achieve a useful output power of, say, 3.5 KW with a voltage drop of only 5%, the usual practice is to use a permanent magnet alternator capable of developing far more than 3.5 KW. Such an alternator thus has considerable excess capacity that is never utilized, and is physically larger, heavier and more expensive than an alternator having a maximum power capability of 3.5 KW. The challenge, therefore, is to operate an alternator at up to its peak power capabilities while still keeping the output frequency and voltage within acceptable limits.
- the invention provides an engine-driven generator comprising an internal combustion engine and an alternator coupled to the engine for developing a first alternating potential having a frequency and no-load voltage dependent on the speed of the engine.
- Circuitry is provided for converting the first alternating potential into a second alternating potential of lower frequency, the second alternating potential comprising a predetermined number of positive-polarity half-cycles of the first alternating potential followed by an equal number of negative polarity half-cycles of the first alternating potential.
- Logic is provided for increasing or decreasing the predetermined number in accordance with the frequency of the first alternating potential so as to maintain the frequency of the second alternating potential between pre-established upper and lower frequency limits.
- Still additional logic is provided for deleting, from the second alternating potential, selected ones of the positive and negative-polarity half-cycles of the first alternating potential so as to maintain the RMS voltage of the second alternating potential between pre-established upper and lower voltage limits.
- the invention also provides a method of operating an engine-driven generator so as to generate an alternating potential having a frequency and voltage that remain within predetermined limits despite varying loads.
- the method comprises the step of turning an alternator with an engine to develop a first alternating potential having a frequency and no-load voltage related directly to the engine speed.
- the method further comprises the step of converting the first alternating potential into a second alternating potential of lower frequency wherein each positive-polarity half-cycle of the second alternating potential comprises a predetermined number of positive-polarity half-cycles of the first alternating potential, and wherein each negative-polarity half-cycle of the second alternating potential comprises an equal number of negative-polarity half-cycles of the first alternating potential.
- the method further comprises the step of increasing the predetermined number with increasing frequency of the first alternating potential so that the frequency of the second alternating potential remains within predetermined upper and lower frequency limits.
- the method further comprises the step of eliminating from the positive and negative-polarity half-cycles of the second alternating potential, selected ones of the positive and negative-polarity half-cycles of the first alternating potential so that the RMS voltage of the second alternating potential remains substantially between predetermined upper and lower voltage limits.
- FIG. 1 is side elevation view of an engine-driven generator constructed in accordance with various aspects of the invention.
- FIG. 2 is a graph showing unregulated alternator output voltage as a function of load current at various engine speeds.
- FIG. 3 is a simplified functional block diagram of the engine-driven generator constructed in accordance with various aspects of the invention.
- FIG. 4 is a functional block diagram of an AC to AC converter incorporated in the engine-driven generator embodying various features of the invention.
- FIGS. 5A-5E are graphs showing various waveforms useful in understanding the method for providing frequency regulation in the engine-driven generator.
- FIGS. 6A-6C are graphs showing various waveforms useful in understanding the method for providing over voltage protection in the engine-driven generator.
- FIG. 7 is a graph showing output voltage, engine speed and output frequency versus load current for one embodiment of the engine-driven generator, useful in understanding the operation thereof.
- the power generator 10 generally includes an internal combustion engine 12 coupled to a permanent magnet alternator 14.
- the engine 12 and alternator 14 are preferably those shown and described in the copending applications of Kern, et al. entitled, respectively, "Internal Combustion Engine for Portable Power Generating Equipment” and “Permanent Magnet Alternator,” the specifications of which are incorporated by reference herein.
- the engine 12 turns the permanent magnet alternator 14 to develop a first alternating current or potential (also referred to herein as the "alternator current” and “alternator output”).
- the frequency, as well as the no-load voltage of the first alternating current is directly related to the engine speed, i.e., the frequency and no-load voltage both increase as engine speed increases.
- the power generator 10, in accordance with one aspect of the invention further includes a control and regulator circuit 16 that converts the first alternating current developed by the alternator into a second, lower frequency, alternating current or potential (e.g, 60 Hz 120 VAC) useful for powering various electrical devices.
- the second alternating current is also referred to herein as the "Generator Current” or “Generator Output”).
- the internal combustion engine 12 in the power generator 10 does not operate at a fixed, constant speed, but, rather, operates at a speed that varies in accordance with the load current.
- the engine speed is relatively low.
- the engine speed is higher.
- the frequency and voltage of the alternating current produced by the generator 10 remain relatively constant and substantially within pre-established upper and lower limits (e.g., 56-60 Hz, and 108-127 V rms ). This remains true even though the frequency and voltage of the alternator output changes greatly with changing engine speed.
- Such voltage and frequency regulation is accomplished by the control and regulator circuit 16 which controls engine speed and converts the alternator current into the generator output current.
- the general function of the control and regulator circuit 16 can best be understood by reference to FIG. 2, which shows the relationship between the alternator output voltage versus alternator load current at various engine speeds.
- One characteristic of the permanent magnet alternator 14 is that the alternator output frequency and voltage are direct functions of engine speed.
- Another characteristic is that, at a given engine speed, the output or load voltage drops with increasing load current. For example, at an engine speed of 2520 rpm, the alternator output voltage drops from a maximum alternator output voltage of 110 V rms (no-load) to 90 V rms when the load current is 15 amperes.
- the alternator voltage drops between 118 V rms (no-load) to 90 V rms at 20 amperes.
- the alternator output frequency is a direct function of engine speed.
- the output frequency in Hertz
- the alternator output frequency varies from 336 Hz. at an engine speed of 2520 rpm, to 540 Hz. at an engine speed of 4050 rpm.
- the generator output frequency is lower than the alternator output frequency and is derived by frequency dividing the A-C alternator output by a whole number or integer divisor.
- the alternator output is not directly usable without further voltage and frequency conversion and regulation.
- FIG. 2 shows that such an output can be obtained provided that the engine 12 is operated within predetermined upper and lower speed ranges that depend on the load current. For example, if the load current is 10 amperes, the desired generator output can be kept within the voltage limits by operating the engine 12 between approximately 2940 rpm and 3150 rpm.
- FIG. 2 shows that this requirement also imposes limits on the available engine operating speeds.
- the generator output current is derived by frequency dividing the alternator output current by the integer 6, the requirement that the output frequency remain between 56 Hz. and 60 Hz. requires that the engine be operated between the speeds of 2520 rpm and 2700 rpm.
- the divisor is the integer 7 the engine must operate between the speeds of 2940 rpm and 3150 rpm. Still higher engine speeds can be used by using the integers 8 and 9 as divisors.
- the generator output can be kept within the desired upper and lower current and frequency limits by operating the power generator 10 within the engine speed, load current and frequency divisor specifications shown in the dark shaded regions of FIG. 2.
- the desired voltage and frequency characteristics can be obtained at load currents up to six amperes by using an engine speed up to 2700 rpm and a frequency divisor of 6. If additional current is desired, the engine speed must be increased above 2700 rpm in order to keep the load voltage above 108 V rms . Increasing the engine speed above 2700 rpm while using a frequency divisor of 6 would, however, increase the output frequency above 60 Hz. and thus place the generator output frequency outside the desired range.
- the desired load current can be obtained while maintaining the generator output voltage and frequency within the desired limits.
- load currents greater than approximately 17 amperes in the example shown
- control and regulator circuit 16 of the power generator 10 allows a single permanent magnet alternator 14 to provide up to its maximum available power at any given engine speed while still maintaining the output voltage within tolerable limits.
- the generator 10 includes, in addition to the internal combustion engine (prime mover) 12 and alternator 14, a throttle actuator 18, a bridge control 20, a controlled bridge 22 and a system control circuit 24.
- the throttle actuator 18, which is preferably one such as that shown and described in the aforementioned application of Kern, et al. entitled "Internal Combustion Engine for Portable Power Generating Equipment,” is coupled to the internal combustion engine 12 and increases or decreases the engine speed in accordance with electronic control instructions received from the system control 24.
- the system control 24 also receives inputs indicative of the engine operating conditions and provides additional control commands (e.g., an engine shutdown command in the event oil pressure is lost) to the engine 12.
- the output of the alternator 14 is applied to the controlled bridge 22 which, in known manner, full-wave rectifies the alternator output current to develop a continuous series of unidirectional pulses wherein each of the pulses comprises substantially one half-cycle of the alternator output current.
- the direction of the unidirectional pulses can be controllably reversed to provide either positive going or negative going pulses at the output of the controlled bridge. These pulses are available for application to a load 26.
- the polarity of the unidirectional pulses provided at the output of the controlled bridge 22 is controlled by the bridge control 20 which, in turn, is controlled by the system control 24.
- the bridge control 20 under the direction of the system control 24, periodically reverses the direction of the pulses from the controlled bridge 22 so that the output of the controlled bridge 22 consists of alternating sequences of positive and negative going pulses.
- the transition from positive going pulses to negative going pulses and back again takes place at a cyclical rate substantially equal to the desired output frequency of the generator 10 (e.g., 56-60 Hz.)
- the system control 24 monitors the frequency of the alternator output (which is also indicative of engine speed) as well as the output voltage of the controlled bridge 22. In this manner, the system control 24 simultaneously monitors the output frequency and output (load) voltage provided by the generator 10.
- the control and regulator circuit 16 is shown in greater detail in the system block diagram of FIG. 4.
- the controlled bridge 22 includes a triac switching module 28 that performs the full-wave rectifying function.
- the input to the triac switching module 28 consists of the output of the alternator 14 (FIG. 3), which, in practice, can be a one, two or three phase alternating current.
- the triac switching module 28 includes a plurality of triacs that can be controllably switched to provide, at their outputs, either positive or negative going unidirectional pulses.
- the controlled bridge 22 further includes a zero current detector 30 that detects when the zero current or "cross over" point occurs as the direction of the output current is reversed.
- the bridge control 20 includes triac switching logic 32 for controlling which of the individual triacs are actuated as necessary to achieve the desired current output.
- the bridge control 20 further includes a load current direction determination circuit 34 that responds to the zero current points detected by the zero current detector 30 to determine whether the load voltage and current have opposite polarity and whether triac inversion is required.
- the system control 24 includes a zero voltage crossing detector 36 that detects the zero voltage cross-over points of the alternator output potential. This enables the system control 24 to count the individual half cycles of the alternator potential.
- the system control 24 further includes frequency measuring logic 38 that measures the period of these cross over points.
- the system control 24 After measuring the frequency of the alternator voltage, the system control 24 next calculates (40) by what integer the alternator output frequency must be divided in order to produce an alternating current within the desired frequency range, e.g., 56-60 Hz.
- the number or divisor N thus calculated is loaded into a counter circuit 42 that, in response to the signal developed by the zero voltage crossing detector 36, counts the requisite number N of half cycles of the alternator output current.
- the counter 42 Upon reaching the required count, the counter 42 then signals the triac switching logic 32 of the bridge control 20 to reverse the voltage provided at the output of the controlled bridge 22. Additionally, the counter 42 signals the load current direction/inversion determination circuit 34 which signals the triac switching logic 32 to cause triac inversion.
- FIG. 5 An alternator 10 providing a two phase output is utilized.
- the alternator output voltage is illustrated in FIG. 5(a).
- the output of the controlled bridge 22 is shown in FIG. 5(b).
- the output of the controlled bridge 22 consists of a predetermined number of positive-polarity half-cycles of the alternator voltage, followed by an equal number of negative-polarity half-cycles of the alternator voltage. This sequence is repeated over and over, and the repetition rate constitutes the output frequency of the generator.
- each half-cycle of the generator output includes six half-cycles of the alternator output.
- the minimum permissible engine speed is 3360 rpm (alternator frequency of 448 Hz.) as any lower engine speed would then place the generator frequency below the low frequency limit of 56 Hz. Accordingly, in the particular embodiment shown and described, certain engine speed ranges, i.e., 2700-2940 rpm, 3150-3360 rpm and 3600-3780 rpm, are unavailable regardless of the 10ad current and regardless of the particular divisor in use at any time.
- the alternator voltage is within acceptable limits and each of the half-cycles determined by the divisor N are included in the generator output.
- the deletion of certain cycles of the alternator output from the generator output can be implemented through suitable control of the triacs in the controlled bridge 22.
- FIG. 7 The overall operation of one representative example of an engine-driven generator 10 constructed in accordance with the invention is shown in FIG. 7.
- This generator 10 is intended to provide up to 3.5 kilowatts while maintaining an RMS output voltage between 108 and 120 volts and an output frequency between 56 and 60 Hz.
- Such a generator incorporates a sixteen pole, two phase permanent magnet alternator 14 that provides eight cycles of alternating current in each phase per revolution of the alternator rotor.
- the engine operates at 2520 rpm and the divisor N is 6. With an engine speed of 2520 rpm, the output frequency is 56 Hz. As the output current rises, the engine speed increases to 2700 rpm while the frequency increases from 56 Hz. to 60 Hz.
- the load voltage varies from a high of 120 volts (no-load) to a low of 108 volts when the load current reaches eight amperes.
- the divisor N At load currents between eight and ten amperes, the divisor N is increased to 7 and the engine speed is increased to 2940 rpm which places the output frequency at 56 Hz. Between eight and ten amperes, the divisor N remains at 7 and the engine speed and the output frequency remain constant.
- the engine speed increases between 2940 rpm and 3150 rpm with increasing load current. This, of course, simultaneously increases the output frequency from 56 Hz. to 60 Hz. By so increasing the engine speed, the load voltage can be maintained within a preferred range of between 113 volts and 120 volts without approaching the low voltage limit of 108 volts. Once the engine speed reaches 3150 rpm, however, any further increase would place the output frequency above 60 Hz. Accordingly, with load currents between fourteen and sixteen amperes, the engine speed is maintained constant at 3150 rpm and the output voltage decreases with decreasing load current until the output voltage reaches 108 volts.
- the engine speed can vary over a wide range.
- the output frequency it is possible for the output frequency to fall outside the preferred range. It will be apparent to those skilled in the art that, by appropriately timing the change in the divisor N it is possible (and preferred) to keep the output frequency at or below 60 Hz.
- the control circuitry 16 of the engine-driven generator is preferably implemented by a suitably programmed, microprocessor-based system.
- the use of a microprocessor based control circuit provides considerable design flexibility and permits the engine driven generator to be particularly tailored for specific applications and tasks. Although specific voltages, currents, frequencies and engine operating speeds have been described for purposes of example, it will be appreciated that the system operating parameters can be selected to meet particular application and design criteria. Of course, in selecting particular engine and alternator combinations, consideration should be given to ensuring that the engine will be able to turn the alternator at all engine speeds and conditions of alternator load.
- the engine-driven generator 10 herein shown and described provides numerous advantageous. Because the permanent magnet alternator 14 can be operated at up to its maximum power output point, a smaller and lighter alternator 14 can be used to achieve a given power level that in prior designs wherein the alternators had considerable unused, excess capacity. The use of a smaller alternator 14 reduces the physical size and weight of the generator 10 and significantly reduces manufacturing costs. Furthermore, because it is no longer necessary to operate the internal combustion engine 12 at a constant fixed speed, greater fuel economy is realized and less noise is produced while the generator is in operation and use. Finally, engine life is increased by reason of the slower operating speeds at smaller loads
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- Power Engineering (AREA)
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- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Control Of Eletrric Generators (AREA)
Abstract
Description
Claims (14)
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
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US07/897,380 US5376877A (en) | 1992-06-11 | 1992-06-11 | Engine-driven generator |
PCT/US1993/005638 WO1993026082A1 (en) | 1992-06-11 | 1993-06-11 | Engine-driven generator |
US08/282,514 US5504417A (en) | 1992-06-11 | 1994-07-27 | Engine-driven generator |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US07/897,380 US5376877A (en) | 1992-06-11 | 1992-06-11 | Engine-driven generator |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US08/282,514 Continuation-In-Part US5504417A (en) | 1992-06-11 | 1994-07-27 | Engine-driven generator |
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US5376877A true US5376877A (en) | 1994-12-27 |
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Application Number | Title | Priority Date | Filing Date |
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US07/897,380 Expired - Lifetime US5376877A (en) | 1992-06-11 | 1992-06-11 | Engine-driven generator |
US08/282,514 Expired - Fee Related US5504417A (en) | 1992-06-11 | 1994-07-27 | Engine-driven generator |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
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US08/282,514 Expired - Fee Related US5504417A (en) | 1992-06-11 | 1994-07-27 | Engine-driven generator |
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WO (1) | WO1993026082A1 (en) |
Cited By (37)
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US5502368A (en) * | 1994-06-06 | 1996-03-26 | Ecoair Corp. | Hybrid alternator with voltage regulator |
US5504417A (en) * | 1992-06-11 | 1996-04-02 | Generac Corporation | Engine-driven generator |
US5546901A (en) * | 1995-06-30 | 1996-08-20 | Briggs & Stratton Corporation | Engine housing for an engine-device assembly |
US5631543A (en) * | 1995-03-21 | 1997-05-20 | Homelite Inc. | Electronic voltage regulator and idle control circuit for generators |
US5635768A (en) * | 1994-04-30 | 1997-06-03 | Aisin Seiki Kabushiki Kaisha | Gas turbine engine driven auxiliary electric power unit with turbine speed controlled in response to generator output current |
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US5635768A (en) * | 1994-04-30 | 1997-06-03 | Aisin Seiki Kabushiki Kaisha | Gas turbine engine driven auxiliary electric power unit with turbine speed controlled in response to generator output current |
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US6555929B1 (en) | 2000-10-24 | 2003-04-29 | Kohler Co. | Method and apparatus for preventing excessive reaction to a load disturbance by a generator set |
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US6701221B1 (en) | 2000-10-24 | 2004-03-02 | Kohler Co. | Method and apparatus for preventing excessive heat generation in a alternator of a generator set |
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US20030189338A1 (en) * | 2001-04-16 | 2003-10-09 | Briggs & Stratton Corporation | Apparatus having an electrical machine |
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